Polymer Battery Support Network for Swelling and Delamination
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Solution Overview
Problem
Conventional metal-based compressive structures in batteries, such as lithium-based batteries, contribute significantly to weight and cost due to volumetric changes during operation, leading to separation and delamination of electrodes, which degrades ion transfer paths and results in cell failure.
Innovation Solution
A polymeric support system is used as a compressive structure, comprising a continuous network of polymers that provides mechanical strength through anchoring to current collectors, allowing for tensile strength equivalent to external pressure, and can be cured using optical, chemical, or kinetically controlled methods, reducing overall battery weight and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal-based compressive structures are used to prevent electrode separation and delamination, then mechanical strength and structural stability are improved, but battery weight increases substantially (up to 65% of total battery weight)
Solution Approach 1:
The patent changes the material parameter from metal to polymer, fundamentally altering the density and mechanical properties. The polymer support structure maintains necessary mechanical strength while reducing density by a factor of 2-3 compared to metal, directly resolving the weight-strength contradiction
Solution Approach 2:
The patent employs composite material structures where polymer matrices are combined with reinforcing elements such as fibers or nanomaterials. This composite approach enables the polymer support structure to achieve metal-level mechanical strength while retaining the inherent weight advantage of polymer materials
2Reliability
If metal-based compressive structures are used to maintain cell integrity during volumetric change, then reliability is improved, but manufacturing cost increases due to material cost and machining cost
Solution Approach 1:
The patent changes the material parameter from metal to polymer, which fundamentally alters both the mechanical performance and manufacturability. Polymers offer inherent corrosion resistance, easier forming capabilities, and reduced machining requirements, directly addressing the cost-reliability contradiction
Solution Approach 2:
The patent employs flexible polymer support structures that can be formed as thin-walled casings or internal reinforcement layers. These flexible polymer components maintain cell integrity during volumetric changes while requiring minimal material and processing, thereby reducing manufacturing cost while preserving reliability
3Weight of moving object
If polymer-based support system is used to reduce battery weight, then weight is reduced (up to 15% reduction), but mechanical strength may be insufficient compared to metal structures
Solution Approach 1:
The patent employs composite material structures where polymer matrices are combined with reinforcing elements such as fibers or nanomaterials. This composite approach enables the polymer support structure to achieve metal-level mechanical strength while retaining the inherent weight advantage of polymer materials
Solution Approach 2:
The patent divides the support structure into segmented or lattice configurations that optimize structural efficiency. This segmentation allows the polymer material to achieve higher specific strength by distributing loads through optimized geometric patterns, resolving the strength-weight contradiction
4Ease of manufacture
If polymeric precursors are applied before battery assembly to enable post-fabrication curing, then ease of manufacture is improved, but process complexity increases due to additional curing steps
Solution Approach 1:
The patent applies polymeric precursors in a liquid or pre-polymerized state during the battery assembly process, before final curing. This preliminary action allows the precursors to be easily incorporated into the battery structure, and the subsequent curing step (triggered by heat, light, or chemical catalysts) completes the process, simplifying overall manufacturing while adding minimal complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polymeric support system effectively mitigates volumetric changes, reduces battery weight by up to 15%, enhances mechanical strength, and simplifies fabrication, while maintaining favorable electrochemical conditions, improving the operational efficiency and safety of batteries.
Implementation Method 1
the polymeric support system may be cured using optical energy (e.g., gamma, X-ray, ultraviolet, etc.)
Implementation Method 2
the polymeric support system may be chemically cured
Implementation Method 3
kinetically controlled curing may be driven in whole or part by heat generated during the first few cycles of a battery's operational lifespan
Data Source
AI summary
Methods of fabricating electrochemical cells employing polymeric support systems rather than metal-based materials as a protective mechanism against mechanical and electrical damage include assembling components of the electrochemical cell. In addition to an anode, a cathode, and a porous separator, the components include a continuous network of precursors of a polymer support system. The continuous network is arranged in continuous pathway(s) extending throughout the interior of the electrochemical cell. Batteries may be provided with the continuous network of precursors in place, i.e., uncured, and curing may be performed post-fabrication and/or sale. Alternatively, curing may be performed during fabrication (or prior to sale), resulting in a continuous network of polymeric pathways extending throughout the volume of the cell and providing mechanical strength, e.g., by penetrating and physically coupling the various components of the cell. Curing may be performed using various mechanisms, including thermal, kinetic, chemical, and optical.